S7-400 - Hardware and Installation - Siemens

1 Preface, Contents SIMATIC. 1. Product Overview Automation System S7-400 2. Installing the S7-400 . Hardware and Installation 3. Addressing the S7-400 . Installation Manual 4. Wiring the S7-400 . 5. Networking 6. Commissioning 7. Maintenance Appendices Assembling and Installing Systems A. Guidelines for Handling Electro- statically-Sensitive Devices (ESD). B. Glossary, Index This manual is part of the documentation package with the order number 6ES7498-8AA05-8BA0. 11/2006. A5E00850741-01. Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring to property damage only have no safety alert symbol. The notices shown below are graded according to the degree of danger. Danger ! indicates that death or severe personal injury will result if proper precautions are not taken.

2 Warning ! indicates that death or severe personal injury may result if proper precautions are not taken. Caution ! with a safety alert symbol indicates that minor personal injury can result if proper precautions are not taken. Caution without a safety alert symbol indicates that property damage can result if proper precautions are not taken. Notice indicates that an unintended result or situation can occur if the corresponding notice is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notices in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards.

3 Prescribed Usage Note the following: Warning ! This device and its components may only be used for the applications described in the catalog or the technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens . Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance. Trademarks All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaim of Liability We have reviewed the contents of this publication to ensure consistency with the Hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in sub- sequent editions.

4 Siemens AG A5E00850741-01 Copyright E Siemens AG 2006. Automation and Drives 11/2006 Technical data subject to change Postfach 4848. 90437 N RNBERG. GERMANY. Preface Purpose of the Manual The manual contains reference information on operator actions, descriptions of functions and technical specifications of the central processing units, power supply modules and interface modules of the S7-400 . How to configure, assemble and wire these modules (and other) in an S7-400 . system is described in the Installation manuals for each system. Required Basic Knowledge You will need general knowledge of automation to understand this manual. Prerequisite is also sufficient knowledge in the use of computers or PC-type equipment (programming devices, for example) with Windows 2000 or XP. operating system. The S7-400 system is configured in STEP 7 standard software. You should therefore have sufficient knowledge of this standard software. This knowledge is provided in the Programming with STEP 7 manual.

5 Please note the information on the safety of electronic control systems in the appendix of this manual, in particular when operating an S7-400 in safety-relevant areas. Scope of this Manual The manual applies to the S7-400 automation system. Approvals You can find details on approvals and standards in the Module Data reference manual. Place of this Documentation in the Information Environment This manual is part of the documentation package for S7-400 . System Documentation Package S7-400 S7-400 Programmable Controller; Hardware and Installation S7-400 Programmable Controllers; Module Data Automation System S7-400 ; CPU Data S7-400 Instruction List Automation System S7-400 Hardware and Installation A5E00850741-01 iii Preface Navigating The manual offers the following access help to make it easy for you to find specific information: At the start of the manual you will find a complete table of contents and a list of the diagrams and tables that appear in the manual. An overview of the contents of each section is provided in the left column on each page of each chapter.

6 You will find a glossary in the appendix at the end of the manual. The glossary contains definitions of the main technical terms used in the manual. At the end of the manual you will find a comprehensive index which gives you rapid access to the information you need. Recycling and Disposal The S7-400 is low in contaminants and can therefore be recycled. To recycle and dispose of your old device in an environment-friendly manner, please contact a disposal company certified for disposal of electronic waste. Further Support If you have any technical questions, please get in touch with your Siemens representative or responsible agent . You will find your contact person at: You will find a guide to the technical documentation offered for the individual SIMATIC Products and Systems here at: The online catalog and order system is found under: Training Centers Siemens offers a number of training courses to familiarize you with the SIMATIC S7. automation system. Please contact your regional training center or our central training center in D 90327 Nuremberg, Germany for details: Telephone: +49 (911) 895-3200.

7 Internet: Automation System S7-400 Hardware and Installation iv A5E00850741-01. Preface Technical Support You can reach the Technical Suport for all A&D products Via the Web formula for the Support Request Phone: + 49 180 5050 222. Fax:+ 49 180 5050 223. Additional information about our Technical Support can be found on the Internet pages: Service & Support on the Internet In addition to our documentation, we offer our Know-how online on the internet at: where you will find the following: The newsletter, which constantly provides you with up-to-date information on your products. The right documents via our Search function in Service & Support. A forum, where users and experts from all over the world exchange their experiences. Your local representative for Automation & Drives. Information on field service, repairs, spare parts and more under Services . Automation System S7-400 Hardware and Installation A5E00850741-01 v Preface Automation System S7-400 Hardware and Installation vi A5E00850741-01.

8 Contents 1 Product Overview .. 1-1. 2 Installing the S7-400 .. 2-1. S7-400 Installation .. 2-2. Installing the Central Rack (CR) and Expansion Rack (ER) .. 2-6. Segmented CR .. 2-8. Subdivided CR .. 2-9. Mounting and Grounding the Racks .. 2-10. Chassis Terminal Connection in the Non-Isolated Configuration .. 2-16. Methods of Ventilation .. 2-18. Changing the Ventilation with the Cable Duct and Fan Subassembly .. 2-20. Installing the Fan Subassembly .. 2-22. Installing the Cable Duct .. 2-24. Choosing and Setting up Cabinets with the S7-400 .. 2-25. Rules for the Arrangement of Modules .. 2-29. Installing Modules in a Rack .. 2-30. Marking the Modules with Slot Labels .. 2-33. Methods of Expansion and Networking .. 2-34. Accessories .. 2-35. 3 Addressing the S7-400 .. 3-1. Geographical and Logical Addresses .. 3-2. How to Determine the Default Address of a Module .. 3-4. How to Determine the Default Address of a Channel .. 3-6. 4 Wiring the S7-400 .. 4-1. Supplying Power to Modules.

9 4-2. Choosing the Power Supply Module .. 4-3. Choosing the Load Current Power Supply .. 4-4. Assembling an S7-400 with Process I/Os .. 4-5. Assembling an S7-400 with Grounded Reference Potential (M) .. 4-7. Assembling an S7-400 with Ungrounded Reference Potential (Ungrounded Configuration) .. 4-8. Assembling an S7-400 with Isolated Modules .. 4-10. Parallel Wiring of Digital S7-400 Outputs .. 4-12. Automation System S7-400 Hardware and Installation A5E00850741-01 vii Contents Grounding .. 4-13. Interference-Free Configuration for Local and Remote Connections .. 4-15. Wiring Rules .. 4-17. Wiring the Power Supply Module .. 4-18. Wiring the Signal Modules .. 4-22. Wiring the Front Connector, Crimping .. 4-24. Wiring the Front Connector, Screw Terminals .. 4-25. Wiring the Front Connector, Spring-Type Terminals .. 4-26. Fitting the Strain Relief .. 4-28. Labeling a Front Connector .. 4-29. Fitting the Front Connector .. 4-32. Interconnecting the CR and ER(s) .. 4-35. Setting the Fan Subassembly to the Line Voltage and Wiring It.

10 4-37. Cable routing in cable ducts or fan subassemblies .. 4-38. Routing Fiber-Optic Cables .. 4-38. 5 Networking .. 5-1. Configuring a Network .. 5-2. Fundamentals .. 5-3. Rules for Configuring a Network .. 5-7. Cable Lengths .. 5-15. PROFIBUS-DP Bus Cables .. 5-18. Bus Connectors .. 5-19. RS 485 Repeater / Diagnostics Repeater .. 5-21. PROFIBUS-DP Network with Fiber-Optic Cables .. 5-22. Fiber-Optic Cables .. 5-24. Simplex Connectors and Connector Adapter .. 5-26. Connecting a Fiber-Optic Cable to the PROFIBUS Device .. 5-28. 6 Commissioning .. 6-1. Recommended Procedure for First Startup .. 6-2. Checks Prior to Switching On for the First Time .. 6-3. Connecting a Programming Device (PG) to an S7-400 .. 6-5. Switching On an S7-400 for the First Time .. 6-6. Resetting the CPU with the Mode Selector Switch .. 6-7. Cold, Warm, and Hot Restarts with the Mode Selector Switch .. 6-10. Inserting a Memory Card .. 6-11. Inserting a Backup Battery (Option) .. 6-13. Starting Up a PROFIBUS-DP Subnet.